Guy wire connector for ceiling fan

ABSTRACT

An apparatus for connecting one or more guy wires to a down rod, the connector having first and second separable portions which form an aperture for receiving the down rod. At least one of the first or second portions includes at least one passage adapted for releasably receiving a portion of the guy wire. The guy wire may include an anchor, and the passage for receiving the guy wire may be adapted for capturing the anchor so as to preclude movement of the guy wire in a radial direction.

The entire disclosures of U.S. patent application Ser. No. 14/439,801and U.S. Provisional Patent Application Ser. Nos. 62/724,386 and62/864,099 are fully incorporated herein by reference.

BACKGROUND

When an environmental control apparatus, such as a ceiling fan, lightfixture, or the like, is installed outdoors, it is inevitably exposed towind forces which may be unpredictable. While it is possible to securethe supporting down rod rigidly to the ceiling to prevent lateralmovement caused by wind, this introduces a risk of applying momentforces to the electrical box or ceiling structure, which they were notdesigned to bear. For this reason, it is desirable in thesecircumstances to secure the down rod with guy wires, which are able todistribute the load of lateral forces broadly across the ceilingstructure, providing robust support to the fan or light without imposingexcessive forces on the ceiling structure.

Typically, the attachment of a guy wire to a down rod is made difficultby the lack of any fixed attachment location. While it is possible todirectly attach guy wire anchors to the sides of the down rod by screwsor similar means, this may result in the radial position of the guywires not being suitably aligned with available attachment points on thebuilding structure; therefore it is more common to use clamps which canbe rotated as necessary to properly orient the guy wires. The use ofclamps, which are secured by friction, permits the guy wire anchors toslide along the axis of the down rod when under load, such as in a windstorm, resulting in the wires becoming slack and failing to performtheir function adequately. In addition, known attachment means tend tobe complex, difficult to install, and often unsightly when installed.

This disclosure addresses these concerns in a novel way, thereby makingguy wires a more attractive and more reliable way of securing a ceilingfan against the possibility of damage from wind when installed outdoors.

SUMMARY

According to a first aspect of the disclosure, an apparatus forconnecting one or more guy wires to a down rod associated with a ceilingfan is disclosed. The apparatus comprises a connector comprising firstand second separable portions which form an aperture for receiving adown rod. At least one of the first or second portions includes at leastone passage adapted for releasably receiving a portion of the guy wire.A second passage may be formed in each portion for receiving a fastener,wherein the passage has a longitudinal axis generally parallel to atangent to the down rod. The first passage may intersect with the secondpassage.

Further, the guy wire may include an anchor, and the passage forreceiving the guy wire may be adapted for capturing the anchor so as topreclude movement of the guy wire in a radial direction. The down rodmay include a projection, and at least one of the first or secondportions may include a groove for receiving the projection of the downrod such that axial movement of the connector is precluded whilerotational movement is permitted.

In another embodiment, the first and second separable portions whichcomprise the connector may be identical. Each of the first and secondportions may comprise an upper part and a lower part. The upper part maybe identical to the lower part.

In another embodiment, at least one of the first or second portions ofthe connector includes at least one passage adapted for releasablyreceiving an end of the guy wire.

Another aspect of the disclosure relates to a method of manufacturingthe first and second portions of the connector, wherein the first andsecond portions are molded components created in a single mold. Theupper part and lower part of each of the first and second portions mayfurther be molded components created in a single mold.

A final aspect of the disclosure relates to a method of supporting aceiling fan. The method comprises assembling a connector to a down rodassociated with the ceiling fan, the connector comprising first andsecond separable portions forming a passage for receiving the down rod.The method further comprises releasably connecting the guy wire to theconnector.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 illustrates an overall first embodiment of a trim guy wireconnector in connection with a ceiling fan.

FIG. 2 illustrates an overall view of a first embodiment of a trim guywire connector, as assembled on a typical down rod, with guy wiresextending outwards in four directions.

FIG. 3 shows the assembly of FIG. 1 in an exploded view, illustratingthe manner in which the various components are assembled.

FIG. 4 illustrates an alternate embodiment of a trim guy wire connector,as assembled on a typical down rod, with guy wires extending in fourdirections.

FIG. 5 shows the assembly of FIG. 3 in an exploded view, illustratingthe manner in which the various components are assembled.

FIG. 6 is a cross-section of the assembly of FIG. 1 , illustrating themanner in which a screw head may engage a groove about the circumferenceof the central opening in the guy wire anchor assembly.

FIG. 7 is a cross-section of the assembly of FIG. 3 , illustrating themanner in which a screw head and associated nut may be located in arecess or groove about the circumference of the central opening in theguy wire anchor assembly.

FIG. 8 is a perspective view of a first separable portion of the trimguy wire connector of FIG. 3 .

FIG. 9 is a top cross-sectional view of the assembly of FIG. 3 , alsohighlighting the alignment features of the guy wire anchor assembly;

FIG. 10 illustrates a guy wire with a ferrule type anchor.

FIG. 11 is a top cross-sectional view of the assembly of FIG. 1 .

FIGS. 12A, 12B and 12C illustrate a seat in the trim guy wire connectorfor the anchor of FIG. 9 .

FIGS. 13 through 16 illustrate an alternate embodiment of the connector.

FIG. 17 illustrates another possible embodiment of the connector.

FIGS. 18 through 21 illustrate an alternate embodiment of the connector.

DETAILED DESCRIPTION

The following description of certain examples of the invention shouldnot be used to limit the scope of the disclosure. Other examples,features, aspects, embodiments, and advantages of the invention willbecome apparent to those skilled in the art from the followingdescription, which includes by way of illustration, one or more of thebest modes contemplated for carrying out the invention. As will berealized, the invention is capable of other different and obviousaspects, all without departing from the invention. Accordingly, thedrawings and descriptions should be regarded as illustrative in natureand not restrictive.

In one embodiment as shown in FIGS. 1-3 , a connector 10 is shown. Theconnector 10 comprises complementary portions 12, 14. When fastenedtogether by fasteners, such as screws 16, the complementary portions 12,14 create a passage 18 for receiving a support for a fan, such as atubular down rod 20 of a ceiling fan 8. As the screws 16 are tightened,the two portions 12, 14 exert a clamping force upon the periphery of thedown rod 20 to secure the connector 10 via frictional engagement to thedown rod.

Each of the two portions 12, 14 may comprise complementary components,which may be arranged as upper and lower parts 12 a, 12 b; 14 a, 14 b inthe typical orientation in connection with a vertically oriented downrod 20, as shown. In this example, the only difference between the upperand lower parts 12 a, 12 b; 14 a, 14 b is that one is threaded toreceive the corresponding threads of an attachment screw 38, while theother has a larger, unthreaded hole 40 in the same location to allowpassage of the shank of the screw from the opposite half. Therefore, theupper and lower parts may both be formed in the same mold or castingdie, with the threaded or enlarged hole being formed as a secondaryoperation on the finished casting. In this way, only one mold or castingdie is needed to produce all four parts comprising the main body of thedevice.

As shown in FIGS. 4-5 , the complementary portions 12, 14 may also beidentical to one another, which may reduce complexity and cost ofproduction. The joined complementary portions 12, 14 of the connector 10may be shaped like a trim piece for the ceiling fan 8, such as in theshape of a bell. For example, the assembled connector 10 may flare froma relatively smaller diameter at a top of the connector to a relativelylarger diameter at a bottom of the connector. The connector 10 may beadapted for connecting to the down rod 20 such that a bottom of theconnector 10 is in contact with an upper housing cover 26 of the ceilingfan 8. In another aspect, the bottom of the connector 10 may not contactthe upper housing cover 26, but may be immediately adjacent the upperhousing cover. For example, the bottom of the connector 10 may be lessthan 10 mm from the upper housing cover 26. More specifically, thebottom of the connector may be less than 5 mm, or more specifically, maybe approximately 4.5 mm from the upper housing cover 26. In this way,the connector 10 may function as an apron with a visually continuoustransition from the down rod 20 to the upper housing cover 26 of the fanhousing.

In addition, a receiver in the form of an annular recess or groove 22 isformed in the interior wall 24 of one or both of the portions 12, 14surrounding the passage 18. A fastener 28 may be attached to the side ofthe down rod 20 and project into the annular recess or groove 22, asshown in FIG. 6 . This fastener 28 may be a screw or bolt and nut asillustrated, and may project radially outward from the down rod 20. Boththe head of the fastener (screw) and associated nut may be located inthis groove 22. The fastener 28 may also adapted to connect the down rod20 to a motor shaft 25 of the ceiling fan 8, as shown in FIG. 7 . Thehead of the screw 28 may extend into an aperture in the down rod 20,thereby creating a positive lock to prevent the assembly from slidingaxially, yet permitting rotational movement.

In a further aspect, the complementary portions 12, 14 may includealignment features adapted to align the complementary portions 12, 14for assembly. As can be seen in FIGS. 8 and 9 , the alignment featuresmay comprise a protrusion 42 and a receiver 44. Each complementaryportion may include both a protrusion 42 and a receiver 44, such thatwhen the complementary portions are mated, the receiver 44 is adapted toaccept the protrusion 42 and restrict relative movement between thecomplementary portions, such as during assembly.

As shown in FIG. 10 , each guy wire 30 has an anchor for associatingwith the connector 10. For example, the wire 30 may be provided with aferrule 32 at one end, which may be formed in the shape of a ball orflange of larger diameter than the wire itself.

As demonstrated in FIGS. 11 and 12 , passages in the form of tubularchannels 34 are formed within the portions 12, 14 of the connector 10 topermit passage of the guy wires. These channels 34 are configured suchthat so that their inner end, adjacent to the passage 18 in theassembly, is large enough to accommodate the larger diameter of theferrule 32, while the outer portion of the channels is smaller indiameter so that it accommodates the wire itself but does not permitpassage of the anchor through the channel. When each guy wire 30 ispassed through its corresponding channel 34, it becomes captive as theferrule 32 enters the larger inboard end of the channel and encountersthe restriction of the reduced diameter of the outboard portion of thechannel. Hence, movement in the radial direction is reliably resisted.

The geometric arrangement of the guy wire channels 34 may be such thatthe wire 30 exits the connector 10 through the same peripheral aperture36 accommodating the attachment screw, as can be seen in FIG. 10 (andwhich extends such that a longitudinal axis of the aperture 36 isgenerally parallel with a line tangent to the down rod 20). Hence, thechannels 34 may be said to intersect with the apertures 36, which thusalso form passages. This simplifies the overall shape of the device andprovides uniform radial spacing from each guy wire 30 to the next aroundthe perimeter.

Using the above combination of features results in a connector 10providing several advantages heretofore unknown. First of all, securityof attachment is not dependent on friction alone, and the guy wires willremain positively attached even if the screws holding the two halves ofthe connector 10 together should become loose. At the same time, becausethe engagement with the fastener 28 may be established within acontinuous circumferential groove 22, the feature does not impose anyrestriction on the rotational orientation of the assembly, so that thewires 30 may be directed to the most optimal locations on the buildingstructure at the time of installation.

In an alternate embodiment, as shown in FIGS. 13-16 , the connector 100for guy wires 130 is configured to fit a smaller diameter down rod 120.In this embodiment, the upper and lower parts 112 a, 112 b; 114 a, 114 bof each portion or section 112, 114 of the device are not identical andrequire separate molds or casting dies, and there are other minor detaildifferences resulting from the difference in scale; but theconfiguration is conceptually similar to the first embodiment describedabove, in that one of the portions 112, 114 includes an annular groove122 for permitting rotation relative to the down rod 120, but resistingmovement in an axial direction.

FIG. 17 illustrates a further embodiment in which the connector 200 ismade of two identical portions or halves 212, 214. Each includes areceiver, such as a pocket 216, for receiving a nut 218, which thus mayreceive the fastener, such as bolt 220 associated with the other portionof the connector. The receiver 216 may be of a diameter such that thenut 218 is received therein, but then held against relative rotation toallow for threading of the fastener (bolt 220). A cutout 222 on theopposite side is adapted to receive the pocket 216 when the portions orhalves 212, 214 are mated. Using this arrangement, all four portionsforming the connector may be made using a single mold, thereby reducingmanufacturing complexity and expense.

In another embodiment, as shown in FIGS. 18-21 , a guy wire trimconnector 310 may be adapted for connecting to a second down rod 320 inorder to secure guy wires 330 thereto. The second down rod 320 may be awide down rod, such as one having a diameter of approximately 45 mm. Theguy wire trim connector 310 illustrated in FIGS. 17-20 may include anumber of features corresponding to those of the first guy wire trimconnector 10 of FIGS. 1-12 , and are illustrated with correspondingreference numerals. Unless indicated otherwise, the correspondinglynumbered elements of the connector 310 of FIGS. 17-20 parallel andfunction similarly to those elements of connector 10 of FIGS. 1-12 .

The second down rod 320 may include an outer diameter that is largerthan an outer diameter of the motor shaft 324. As can be seen in FIG. 19, the second down rod 320 may include an inner diameter spaced from, andwith a gap between it and the outer diameter of the second down rod 320.The motor shaft 324 may be adapted to connect to the inner diameter ofthe second down rod 320 via a fastener 328. The outer diameter of thesecond down rod 320 may include an outer aperture, and the innerdiameter may include an inner aperture, which may be aligned with theouter aperture. This inner aperture may be aligned with a motor shaftaperture, such that the fastener 328 may pass through the inner apertureof the second down rod 320 and the motor shaft aperture, as illustratedin FIG. 20 . In one aspect, the outer aperture of the down rod 320 maybe larger than the inner aperture of the second down rod, such that thefastener 328 may pass fully through the outer aperture, and be retainedentirely within the inner diameter of the second down rod 320. Such aconfiguration may leave the outer aperture of the second down rod 320open upon assembly of the fan with the mount.

As with the first embodiment of the connector 10, the connector 310 mayinclude a wall or projection 326, which may form a recess. As shown inFIG. 20 , the projection 326 may be adapted to extend into the circularaperture 318 for the down rod 320. Upon assembly, the projection 326 maybe adapted to align with the outer aperture of the down rod 320. Thus,upon assembly, the complementary portions 312, 314 of the connector 310may be longitudinally fixed on the down rod so as to preventlongitudinal movement of the connector 310. In one aspect the projection326 may include an internal recess, which may engage the fastener 328.In another aspect, as illustrated, the projection 326 may not engage thefastener 328 upon assembly.

Each of the following terms written in singular grammatical form: “a”,“an”, and the”, as used herein, means “at least one”, or “one or more”.Use of the phrase “One or more” herein does not alter this intendedmeaning of “a”, “an”, or “the”. Accordingly, the terms “a”, “an”, and“the”, as used herein, may also refer to, and encompass, a plurality ofthe stated entity or object, unless otherwise specifically defined orstated herein, or the context clearly dictates otherwise. For example,the phrases: “a unit”, “a device”, “an assembly”, “a mechanism”, “acomponent, “an element”, and “a step or procedure”, as used herein, mayalso refer to, and encompass, a plurality of units, a plurality ofdevices, a plurality of assemblies, a plurality of mechanisms, aplurality of components, a plurality of elements, and, a plurality ofsteps or procedures, respectively.

Each of the following terms: “includes”, “including”, “has”, “having”,“comprises”, and “comprising”, and, their linguistic/grammaticalvariants, derivatives, or/and conjugates, as used herein, means“including, but not limited to”, and is to be taken as specifying thestated components), feature(s), characteristic(s), parameter(s),integer(s), or step(s), and does not preclude addition of one or moreadditional component(s), feature(s), characteristic(s), parameter(s),integer(s), step(s), or groups thereof. Each of these terms isconsidered equivalent in meaning to the phrase “consisting essentiallyof.” Each of the phrases “consisting of” and “consists of, as usedherein, means “including and limited to”. The phrase “consistingessentially of” means that the stated entity or item (system, systemunit, system sub-unit device, assembly, sub-assembly, mechanism,structure, component element or, peripheral equipment utility,accessory, or material, method or process, step or procedure, sub-stepor sub-procedure), which is an entirety or part of an exemplaryembodiment of the disclosed invention, or/and which is used forimplementing an exemplary embodiment of the disclosed invention, mayinclude at least one additional feature or characteristic” being asystem unit system sub-unit device, assembly, sub-assembly, mechanism,structure, component or element or, peripheral equipment utility,accessory, or material, step or procedure, sub-step or sub-procedure),but only if each such additional feature or characteristic” does notmaterially alter the basic novel and inventive characteristics orspecial technical features, of the claimed item.

The term “method”, as used herein, refers to steps, procedures, manners,means, or/and techniques, for accomplishing a given task including, butnot limited to, those steps, procedures, manners, means, or/andtechniques, either known to, or readily developed from known steps,procedures, manners, means, or/and techniques, by practitioners in therelevant field(s) of the disclosed invention.

Terms of approximation, such as the terms about, substantially,approximately, generally, etc., as used herein, refer to ±10% of thestated numerical value or as close as possible to a stated condition.

It is to be fully understood that certain aspects, characteristics, andfeatures, of the invention, which are, for clarity, illustrativelydescribed and presented in the context or format of a plurality ofseparate embodiments, may also be illustratively described and presentedin any suitable combination or sub-combination in the context or formatof a single embodiment. Conversely, various aspects, characteristics,and features, of the invention which are illustratively described andpresented in combination or sub-combination in the context or format ofa single embodiment may also be illustratively described and presentedin the context or format of a plurality of separate embodiments.

Although the invention has been illustratively described and presentedby way of specific exemplary embodiments, and examples thereof, it isevident that many alternatives, modifications, or/and variations,thereof, will be apparent to those skilled in the art. Accordingly, itis intended that all such alternatives, modifications, or/andvariations, fall within the spirit of, and are encompassed by, the broadscope of the appended claims.

The invention claimed is:
 1. An apparatus for connecting one or more guywires to a down rod associated with a ceiling fan, comprising: aconnector comprising first and second separable portions togetherforming an aperture for receiving the down rod, at least one of thefirst or second portions adapted to releasably receive a portion of theguy wire; wherein the guy wire has an anchor, and the first or secondportion includes a first passage adapted for capturing the anchor so asto preclude movement in a radial direction.
 2. The apparatus of claim 1,wherein the down rod includes a projection, and at least one of thefirst or second portions includes a groove for receiving the projectionof the down rod so as to preclude axial movement of the connector whilepermitting rotational movement.
 3. The apparatus of claim 1, wherein thefirst and second separable portions are identical.
 4. The apparatus ofclaim 1, wherein each of the first and second portions comprises anupper part and a lower part.
 5. The apparatus of claim 4, wherein theupper part is identical to the lower part.
 6. The apparatus of claim 1,further including a second passage formed in each portion for receivinga fastener, the second passage having a longitudinal axis generallyparallel to a tangent to the down rod.
 7. The apparatus of claim 6,wherein the first passage intersects with the second passage.
 8. Aceiling fan in combination with the apparatus of claim
 1. 9. A method ofmanufacturing the connector of claim 1, comprising molding the first andsecond portions using a single mold.
 10. An apparatus for connecting oneor more guy wires to a down rod having a projection and associated witha ceiling fan, comprising: a connector including first and secondseparable portions together forming an aperture for receiving the downrod, at least one of the first or second portions including a receivercomprising a groove for receiving the projection of the down rod so asto preclude axial movement of the connector while permitting rotationalmovement.
 11. The apparatus of claim 10, wherein at least one of thefirst or second portions includes at least one passage adapted forreleasably receiving an end of the guy wire.
 12. The apparatus of claim11, wherein the guy wire has an anchor, and the passage is adapted forcapturing the anchor so as to preclude movement in a radial direction.13. The apparatus of claim 10, wherein each of the first and secondportions comprises an upper part and a lower part.
 14. A ceiling fan incombination with the apparatus of claim
 10. 15. A method ofmanufacturing the connector of claim 10, comprising molding the firstand second portions using a single mold.
 16. A method of supporting aceiling fan, comprising: assembling a connector to a down rod associatedwith the ceiling fan, the connector comprising first and secondseparable portions forming a first passage for receiving the down rod,the connector further including at least one second passage; andreleasably connecting a guy wire with an anchor to the connector, saidconnecting step comprising capturing the anchor with the second passageof the connector.